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Stair flights and landings are cast into purpose built moulds. Prior to casting, all cast in parts fixed in position and the mould is treated with a mould release agent. Hereafter reinforcement is kept in position and mould sides are fixed. All reinforcement will normally be prepared and prefabricated in our own workshop and placed in the mould using adequate spacers to ensure correct position and cover.

The specially manufactured casting equipment is employed to pour concrete into the moulds. The concrete used in production of these panels is manufactured under controlled conditions in our own batching and mixer plants employed specifically for captive use only. The in house production of concrete ensures highest possible quality. From batching plants, the concrete is transported directly to the casting equipment.

During casting hand held vibrators and fixed table vibrators are used to achieve the best possible compaction. The type of vibration, duration and amplitude of vibration is skillfully fixed based on pre tests and type of element under casting.

After flights and landings are cast, they are covered with polythenesheets to avoid vaporization and left as it is to develop the initial strength. The concrete strength is ensured before the panels are removed from their mould and transported to curing and finishing area.

All precast panels are cured as per BS standard and company procedures. During the curing period, the panels are regularly watered and kept covered with polythene sheets to retail the moisture around panel.

Quality Control

Quality control is performed according to BPC Group standard quality procedures in the well equipped laboratories. The testing equipment is calibrated and maintained at fixed intervals to ensure the test results are at par.

The material used in production of concrete undergoes inspection and testing as per company inspection procedures and British Standards. The reinforcement steel used in the panels is as per British Standards.  

Comprehensive strength of concrete is determined by standard test cubes from the fresh concrete and these are tested in accordance with BS 1881: Part 108:1983 and BS1881: Part 116:1983.

All moulds are individually checked before casting. The final product is checked and inspected to ensure it meets the required finish and is free from any snags.

All stair flights and landings are cured as per British Standards and company procedures. During the curing period, the panels are regularly watered and kept covered with polythene sheets to retail the moisture around panel.

A full schedule of company standard quality control procedures can be requested from the Quality Department.

 

As a special service, we can offer a full Quality Control Report for the individual project consisting of casting dates, cube test and other quality checks for the particular project. This service shall be agreed with our Sales Department.

BPC Group Quality Control System and standard procedures have been certified to meet the requirements of ISO 9001:2000 standard covering design, manufacture and erection of the company's precast components. The ISO 9001:2000 certificate also ensures that the clients are guaranteed a good product and service throughout the entire project.

Quality Management System of BPC Bahrain, UPC Dubai and UPC Abu Dhabi has been certified by DNV  

Transportation and installation

Both flights and landings are normally transported on flat bed trailers and lifted directly from trailer into position.

In order to achieve the exact level required, each unit is placed on PVC or steel shims. The gap between the units and the structure on which it is resting will be filled with relative dry sand cement mortar.

Dowel holes with projecting steel will be grouted using a low shrink easy flow cement mix.